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02 cougar a/c compressor & clutch
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krich
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Dec 14, 2008, 12:53 PM
Post #1 of 17
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02 cougar a/c compressor & clutch
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02 mercury cougar
2.5/6cyl
hello
i've detached the a/c compressor in order to replace the clutch which was bad.
i'm in the process of reattaching the compressor but the 2 lower bolts just will not go in. is there a special tool for this?
also, is there a special tool (i.e. press) to install the clutch?
the clutch assembly was removed with no problem. in the process of replacing with the new one, it seems it will be easier to install if the compressor is reattached but like i mentioned...the 2 lower bolts just will not go in.
what am i doing wrong? if you need more info/details/photos, please ask.
thanks in advance.
krich
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Loren Champlain Sr
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Dec 14, 2008, 12:59 PM
Post #2 of 17
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Re: 02 cougar a/c compressor & clutch
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There is a special tool used to put the clutch assy. back onto the compressor. It is very similar to the one used to put a power steering pump pulley back on. From what I've read here on the site, you may be able to rent one from Auto Zone or another large parts chain. As for the compressor mounting bolts, unsure what the problem may be. Just not lined up right? Pics would help greatly.
Loren
SW Washington
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krich
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Dec 14, 2008, 1:21 PM
Post #3 of 17
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Re: 02 cougar a/c compressor & clutch
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thanks for the quick response.
the pics are attached.
we rented a press from oreilly's for that purpose but nothing in that set was appropriate for this task so we returned it. we asked for further instructions or tools, of course they just work there. there was an a/c guy that happened to be there who said to use a 2x4 to press the clutch back into place which we've tried with no luck.
but the bolts are the strangest thing. they seem to be lined up just right & we've adjusted them a hair or two in all directions but can't seem to get it right. therefore, i've resorted to online expertise since it's sunday & no one is open.
thanks again
krich
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way2old
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Dec 14, 2008, 1:26 PM
Post #4 of 17
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Re: 02 cougar a/c compressor & clutch
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Do you have the old clutch and coil off? If yes, you need to press the coil in place then install the clutch. As far as bolting the compressor back to the block, you just have to wiggle it a little until it slides on the pins. Good luck.
Being way2old is why I need help from younger minds
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krich
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Dec 14, 2008, 1:31 PM
Post #5 of 17
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Re: 02 cougar a/c compressor & clutch
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thanks for the tip & the luck, i think that's what it's gonna take. it sure is stubborn.
krich
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Loren Champlain Sr
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Dec 14, 2008, 1:34 PM
Post #6 of 17
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Re: 02 cougar a/c compressor & clutch
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Great pics, btw. I agree with way2old. Make sure any other mounting bolts are left loose until you get these two started; May help? Good luck.
Loren
SW Washington
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krich
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Dec 14, 2008, 1:55 PM
Post #7 of 17
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Re: 02 cougar a/c compressor & clutch
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thanks folks. really appreciate the input. at least i know i'm not crazy.
hope your holidays are great!
krich
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way2old
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Dec 14, 2008, 2:42 PM
Post #8 of 17
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Re: 02 cougar a/c compressor & clutch
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Just for giggles, see if you can place all 4 bolts in compressor and then line it up by hand threading all 4 to start. Then you can pull it down evenly with tools.
Being way2old is why I need help from younger minds
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Tom Greenleaf
Ultimate Carjunky
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Dec 14, 2008, 7:09 PM
Post #9 of 17
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Re: 02 cougar a/c compressor & clutch
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I see coil is off in that pic and the issue with mounting bolts. Just wiggle around for those bolts as "way2old" said till you get them to grab but don't cross them up either.
How did the clutch come off? I don't know each and every clutch but have the set that always has what's needed to remove and install. The outer plate may have shims you have to pay attention to or gap won't be right. Add or subtract shims to achieve .020 or closer gap or if pressed to adjust do it with a biz card just till it won't fall out of gap. Was the coil even bad? I don't find many bad and just do bearing in the clutch which is more common......
T
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krich
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Dec 14, 2008, 10:18 PM
Post #10 of 17
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Re: 02 cougar a/c compressor & clutch
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well, i'm happy to report.....we finally got the darn thing bolted back!!! and....the clutch installed and....the keeper pin (what a booger!) almost like the bolts. it started up, we charged the freon, it works great.....as long as the a/c is on. we think the center/coil? may be too tight because if the a/c is not on it squeals & the clutch doesn't turn, starts smokin. so the pulley need to be pushed on more?
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krich
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Dec 14, 2008, 10:37 PM
Post #11 of 17
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Re: 02 cougar a/c compressor & clutch
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bearing & coil were bad.
thanks for the adjustment tip. the outer plate is the clutch? (yes, i'm a girl)
i think that could be the problem but we're almost there.
krich
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Attachments:
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Tom Greenleaf
Ultimate Carjunky
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Dec 15, 2008, 7:27 AM
Post #12 of 17
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Re: 02 cougar a/c compressor & clutch
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Ok: I can about see from here that there's almost no "gap" at the clutch which is why is squeels when A/C is OFF as it's just meant to be a free pulley then.
The fix: The center bolt seen below should remove no trouble and even without a puller that outer plate will remove. Don't mess it up prying too hard. Use whatever to give it an even pull and not bend anything. Inside that there should have been small washers (shims) so hold outer plate away from the hub by the .020 which I mentioned. No problem if you don't have a gauge but if a regular business card type paper is sticky to get in that gap it's way too close! If you lost the washers you'll need to measure carefully as they aren't easy to just get those at a hardware store. Generally new they come with ONE. That ONE can be removed in the life of the clutch to reduce the gap before it's "worn beyond saving" it. That washer is inside the hole of the outer plate you removed or lost now. Hope you have it. Use a tiny magnet to get it out ---- it's inside the hole of the old hub and new one may or may not come with any - dunno as I don't buy new clutches ever but rather get them new on whole compressor's and save a basket full of the old good clutches just for this stuff.
I may be wrong - it's only a pic and not a measurement by a look. If you spin the outer plate now with engine off by that center nut you will see what is the outer part of the plate and what is the hub of the clutch. That's the gap area that needs to be adjusted. I can only guess (no charts, books on those - just look at them one by one) that it uses washers to adjust. Some are pressed on by the clutch tool to the specific gap and you leave it there but this looks like the type with spacer washers.
Again - .020 gap or don't waste time and use a biz card. Folded too tight, single thickness is about right. With belt off the pulley with the grooves should spin without touching that outer plate but be close. If way too far the magnetic force won't pull them in which is the more common problem or bearing alone messes up.
Note: Compressors and clutches have two modes - on and off. When compressing the bearing in the clutch is doing nothing and gap means nothing. The shaft of the compressor is the bearing action when engaged. When OFF - the thing is just a dumb pulley and needs to stay just that - just goes along for the ride and holds belt in place acting as just a pully with no regard whether A/C works or not and doesn't care.
Hope I'm not confusing the issue which is possible
Let me/us know and I/we will try harder to get this solved and over with......
T
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krich
User
Dec 16, 2008, 5:11 AM
Post #13 of 17
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Re: 02 cougar a/c compressor & clutch
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yes, that was the problem. once the washer (shim) was installed, it runs great!
thanks so much for everyone's help & suggestions.
i saved a lot of $$ doing it myself w/help. it took a while but it was worth it. couldn't have done it without y'all's help. i really appreciate it.
happy holidays to all.
krich
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way2old
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Dec 16, 2008, 4:46 PM
Post #14 of 17
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Re: 02 cougar a/c compressor & clutch
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Now you can be one of the regulars. These old men need a ladies touch. Closest we got is Tom's kitty. Glad you fixed it and stayed with the project.
Being way2old is why I need help from younger minds
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Loren Champlain Sr
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Dec 16, 2008, 5:15 PM
Post #15 of 17
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Re: 02 cougar a/c compressor & clutch
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Kitty? That's really reaching. 
Loren
SW Washington
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krich
User
Dec 19, 2008, 4:26 AM
Post #16 of 17
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Re: 02 cougar a/c compressor & clutch
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maybe not regular but y'all are entertaining...
it's amazing what air in the tires does. normally, i'm on top of these things but it's a new car to me. with a new a/c clutch & air in the tires.....feels like an suv.  not to mention the gas mileage. maybe i'll give her a bath too, mileage could increase more. haha
krich
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Tom Greenleaf
Ultimate Carjunky
/ Moderator
Dec 19, 2008, 6:02 AM
Post #17 of 17
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Re: 02 cougar a/c compressor & clutch
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Just remember Loren....
"The early bird may get the worm, but the second mouse gets the cheese” – Unknown
That wasn't good enough for Kitty so SHE ate them all before breakfast!
It's always trouble if you mess with Kitty!
Tom
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